Prefabricated door assembly

ABSTRACT

A prefabricated prehung door assembly comprises two complementary frame members each including vertical joint and horizontal head portions together with door casing attached to respective edges thereof. Flat plate clamps are secured along the edges of the jamb and head portion of one frame member and are held by nails driven through the portions and locked by locking perforations in the plate clamps. Door stop strips cooperate with the clamp to facilitate positioning of the two frame members. The assembly is secured to the studs of the door opening by driving the nails into the studs while maintaining the locking engagement of the nails and clamps-the clamps being retained in position against the jamb and head portions.

United States Patent [72] Wayne C. Coykendall 2172 Reed Drive, Denver. Colo 859,855

Sept. 22, 1969 Aug. 17, I971 PREl-ABRICATED DOOR ASSEMBLY 7 Clallns,6 Drawing Figs.

U.S.Cl

Inventor Appl. No. Filed Patented FleldolSearch 3180;52/2

156] References Cited UNITED STATES PATENTS 11/1959 Vietsv 1/1968 Davis.

Primary Erami'ner Kenneth Downey Anomey-McGrew and Edwards ABSTRACT: A prefabricated prehung door assembly comprises two complementary frame members each including verticaljoint and horizontal head portions together with door casing attached to respective edges thereof. Flat plate clamps are secured along the edges of the jamb and head portion of one frame member and are held by nails driven through the portions and locked by locking perforations in the plate clamps. Door stop strips cooperate with the clamp to facilitate positioning of the two frame members. The assembly is secured to the studs of the door opening by driving the nails into the studs while maintaining the locking engagement of the nails and clamps-the clamps being retained in position against the jamb and head portions.

PREFABRICATED DOOR ASSEMBLY This invention relates to prefabricated door assemblies and I particularly to an improved prehung door assembly of the split frame type and which is of simple construction and easily installed.

Various forms of prefabricated door assemblies have been provided heretofore, some including the feature of a split jamb or frame. In general, these assemblies have required parts of special or peculiar configuration and such assemblies have not satisfied the requirements of many applications. Accordingly, it is an object of the present invention to provide an improved prefabricated door assemblyv for facilitating the accurate installation or hanging of doors.

It is another object of this invention to provide an improved prehung door assembly of simple construction which employs conventional'components or elements and which facilitates the time saving installation of doors in building structures.

Briefly, in carrying out the objects of this invention in one embodiment thereof, a prefabricated door assembly is constructed to comprise two complementary frame members, one having jamb and head portions provided with spaced clamps along its inner edge for receiving the corresponding edge of the jamb and head portions of the other frame member. The clamps comprise flat metal plates each having a locking perforation formed therein to receive and lock a finishing nail. The nails also attach a door stop strip to the one frame so that the strip overhangs the frame a substantial distance and the door is hung in the frame and lies against the stop. The nails are driven in far enough to lock on the plates and are ready to be driven into the studding when the door frame is installed. Door casings complete the frames and are in position to lie against the walls on the sides of the door opening. The first frame member with the'door is installed and the nails driven home -in the studdings and locked by the clamps, and the split construction allows the other frame member to be installed with its inner edge guided by the clamps and the overhanging portion of the door stop and to be spaced as required from the other member along their adjacent or abutting edges which are hidden under the door stop.

The features of novelty which characterize this invention are pointed out with particularity in the claims annexed to and forming a part of this specification. I v

The invention itself, however, both as to its organization and method of application, together with further objects and advantages thereof will best be understood upon reference to the following description taken in connection with the accompanyin g drawing in which:

FIG. 1 is a perspective view of a prefabricated door assembly embodying the invention;

FIG. 2 is an enlarged elevation view partly'broken away of the rear side of the lower left-hand corner of the assembly of FIG. 1;

FIG. 3 is a sectional view taken along the line 3-3 of FIG. I after installation of the assembly;

FIG.'4 is an enlarged plan view of one of the'plate clamps of the assembly;

FIG. 5 is a sectional elevation view taken alongthe line 5-5 of FIG.'4; and

FIG. "6 is an enlarged sectional view similar to that of FIG. 3 illustrating another embodiment of the invention.

The prefabricated door assembly illustrated in FIG. 1 comprises a door 10 mounted in a split frame assembly comprising split front andrearcomplemen'tary frame members ll and 12, respectively. Thefront frame member ll comprises jambs l3 and 14 connected by ahead [5 and the frame member '12 comprises jambs or jamb portions -16 and 17 connected by a head or head'portion l8. This'construction provides a'split jamb door assembly in which the two frame members are complementary parts and meetalong their inner edges which are shown in abutment in FIG. 1. The door '10 is hinged onthe jamb portion '17 and rests against a stop which is held in position by a plurality of nails 21 driven 'at spaced intervals along the stop. The jamb l6 and head 18 are also provided with stops in alignment with the stop 20 but which are not visible in FIG. I because they lie in back of the forward frame and top members. Each of the nails 21 passes through the stop 20 and the jamb 17 and is driven sufficiently far to be held by clamping plates 22 lying against the back face of the jamb 17. The similar nails and clips for the jamb 17 are indicated at 23 and 24, respectively, and the clips are arranged to extend over a portion of the adjacent jamb member 13, adjacent head member 15 and the adjacent jamb member 14, the stop member 20 and the other stops also overlap the two jamb members and conceal thesplit from the inside of the door frame.

For handling and shipping purposes, the lower edge of the door opposite the hinges is secured to the opposite frame member and in position against the opposite stop by a metal angle fitting 25 shown in FIG. 2 and which comprises a horizontal portion 26 and a vertical portion 27 forming a T- shape with the portion 26. The lower portion of the side 27 extends below the door and is secured to the jamb member 16 by a double-headed nail 28; the corner of the door fits in the corner of the fitting 25 between the horizontal portion 26 and the vertical portion 27 and against the stop, indicated at 19, and is secured in place by a double-headed nail 30. The portion of the vertical piece 27 of the fitting 25 which extends between the door and the jamb l6 acts as a spacer.

The door frame assembly is completed by finished casing strips or boards nailed or otherwise suitably secured to the respective jamb members. In FIG. 1 the forward face of the door is provided with casings 31, 32 and 33 secured respectively to the jamb 13, the head 15 and the jamb l4 and the rear side ofthe frame assembly is provided with casing strips 34, 35 and 36 similarly secured to the rear edges ofthe jamb 16, head 18 and jamb 17, respectively,

FIG. 3 illustrates the manner in which the frame assembly is mounted on the studding of a doorway. In this figure, the door post is illustrated as comprising two studs 37 and 38 which may, for example, be two-by-fours, secured in the conventional manner for doorway framing. In the illustration sheets of dry wall 40 and 41 are secured on the 'walls overlapping the studs 37 and 38 with edges in alignment with the front'face of the stud 37. The left-hand side of the doorway assembly shown in FIG. 1 is illustrated as mounted on the stud 37. This is accomplished by first positioning the jamb l7 and casing 36 with respect to the doorway, the head and other side of the frame assembly being similarly positioned with respect to the studding at the top and other side of the doorway. When the required spacings of the jambs from the studs have been'determined and the frame placed in this position,'a metal wedge or similar tool or tools specially designed for the purpose is placed between the stud 37 and the clamp plate 22 and the nails 21 driven into the stud 37. In a similar manner the nails 23 and nails in the headpiece 18, indicated in '42 in FIG. 1, are driven into their corresponding stud member. The nails may be driven in part way and the alignment of the door frame checked and then driven in the rest of theway to their finish nail positions in the door stops. As shown in FIGS. 4 and 5 the plate clamps illustrated as one of the clamps 22 comprise flat plates provided with perforations from which portions 43 are bent upwardly and outwardly to provide nail-gripping members then when the nails are driven to the plate the edges about the'perforation grip the 'nail and hold it against reverse movement thereof. The edge of the plate 22 which lies in engagement with the jamb 14 is provided with an upturned portion 44 which facilitates the insertion of the jamb '14 between the plates and the stop member 20 after the first frame member with the door therein has been mounted in place. By holding the plates in position when driving the nails 21 the plates are held firmly against the jamb member 17 and a tight pocket is provided for the jamb member '14. After preliminary positioning of the first jamb member, the double-headed nails 28 and 30 are removed and the door opened outwardly on its hinges one of which is indicated at 45 so that the nails 2'l-are in position for driving without likelihood of damaging the door. When the door section of the frame assembly has been properly positioned it is further secured in any suitable manner as by driving finishing nails 46 through the casing 36 into the stud 3 7.

The second portion of the frame assembly is then positioned between the stop members and the clamps as illustrated by the stop and clamp 22 in FIG. 3 and is moved toward the jamb member 17 until the casing strip 33 is in position against the dry wall 41 whereupon it is secured in place by driving nails 47 into the stud 37. The assembly is now complete. The jamb l7 and the head 18 and jamb 16 are securely held in position by a multiplicity of nails such as the nail 21 driven into the studs and held in the desired spaced relationship by the plate clamps a sufficient number of nails and clamps being employed to assure adequate support of the door frame. Further support is provided by the attaching of the casings 34, 3S and 36 to the stud structure. The jamb member 14 is securely held in its required position by the stops and clamps and by the nailing of the casing 33 to the stud structure.

' The construction of this frame assembly whereby the installationjs made by simple operation of driving nails into the stud structure while maintaining the clamping relationship of the clamps and stops facilitates and simplifies the precise alignment of the door frame and assures that the door hung in the frame will be positioned and securely held as required. This invention thus provides an extremely simple prefabricated prehung door assembly employing conventional door jamb and casings with a split jamb and with the addition of very simple locking clamps or clamping plates which perform the dual function of maintaining the position of the jamb on which the door is hung as well as aligning the other jamb assembly. The split jamb assembly of this invention also eliminates the need for making or adjusting on the job the mitered joints at the upper corners of the frame.

The structure illustrated in FIG. fi'is essentially the same as that illustrated in FIG. 3 and corresponding parts have been designated by the same numerals with the addition of the suffix letter a." For some applications, it has been found desirable to provide increased and more positive positioning of the parts of the assembly by employing ring-type nails as illustrated by the nail 48 which is employed instead of the nail 21 of the modification of FIG. 3. The ring-type nail provides added gripping strength in the stud 37 and also positive positioning of the nail in the clamp projections 43a, either type of finishing nail may, of course, be employed and these nails may be driven in slightly below the surface of the stop member and their presence concealed by putty in the usual manner.

I claim:

1. A prefabricated split frame type of prehung door assembly adapted to be attached to the studs of a doorway comprising two complementary frame members each comprising a pair of jamb portions connected by a respective head portion and door casings attached to the outer edges of the jamb and head portions, the inner edges of said jamb and head portions of said frame members lying in generally abutting relationship, a door hinged on the innerface of one of said jamb portions of one of said members, a plurality of flat metal clamps attached to one of said frame members at spaced intervals about said jamb and head portions thereof and engaging the outer faces of said portions of both frame members adjacent the inner edges thereof, said clamps being in sliding engagement with the other of said frame members, each of said clamps having a perforation therein and adjacent nail-locking members and being attached by a nail driven through the respective one of said portions into locking engagement with said members about said perforation, said nails being driven only partially through said portions whereby they protrude inwardly in posi tion for driving into the studs to constitute an attaching and supporting means between the studs and said one portion upon installation of the door assembly, and door stop strips attached by said nails to said one member adjacent the door and overlapping said portions of both frame members whereby said strips cooperate with said clamps to position said two frame members with respect to one another and conceal the adjacent edges of said portions.

2. A prefabricated door assembly as set forth in claim 1 wherein each of said clamps has its edge adjacent said other frame bent outwardly away from the frame member to provide a guide for further facilitating the fitting of said frame members together.

3. A prefabricated door assembly as set forth in claim 1 wherein said nails are finished nails of the ring shank type.

4. A prefabricated door assembly as set forth in claim 1, including a rightangled metal stop member attached to said door and to the jamb portion opposite the hinged side thereof for retaining said door in position during handling of the assembly.

5.-A prefabricated door assembly as set forth in claim 4 wherein said angled stop member is attached to said door and to the adjacent jamb by double-headed nails.

6. A prefabricated door assembly as set forth in claim 4 wherein said stop member includes an extension of its side engaging said jamb portion and lying between said door and said jamb portion to hold the door and jamb portion in spaced relationship.

7. A prefabricated door assembly as set forth in claim 2 wherein each of said clamps comprises a Hat metal plate having struck out portions forming said perforation and locking members, said members providing nail engaging edges extending away from the plate for affording ready passage of the nail when driven but resisting movement of the nail in the opposite direction whereby a clamping action may be provided in the initial assembly and also after driving of the nail into a stud. 

1. A prefabricated split frame type of prehung door assembly adapted to be attached to the studs of a doorway comprising two complementary frame members each comprising a pair of jamb portions connected by a respective head portion and door casings attached to the outer edges of the jamb and head portions, the inner edges of said jamb and head portions of said frame members lying in generally abutting relationship, a door hinged on the innerface of one of said jamb portions of one of said members, a plurality of flat metal clamps attached to one of said frame members at spaced intervals about said jamb and head portions thereof and engaging the outer faces of said portions of both frame members adjacent the inner edges thereof, said clamps being in sliding engagement with the other of said frame members, each of said clamps having a perforation therein and adjacent naillocking members and being attached by a nail driven through the respective one of said portions into locking engagement with said members about said perforation, said nails being driven only partially through said portions whereby they protrude inwardly in position for driving into the studs to constitute an attaching and supporting means between the studs and said one portion upon installation of the door assembly, and door stop strips attached by said nails to said one member adjacent the door and overlapping said portions of both frame members whereby said strips cooperate with said clamps to position said two frame members with respect to one another and conceal the adjacent edges of said portions.
 2. A prefabricated door assembly as set forth in claim 1 wherein each of said clamps has its edge adjacent said other frame bent outwardly away from the frame member to provide a guide for further facilitating the fitting of said frame members together.
 3. A prefabricated door assembly as set forth in claim 1 wherein said nails are finished nails of the ring shank type.
 4. A prefabricated door assembly as set forth in claim 1, including a right-angled metal stop member attached to said door and to the jamb portion opposite the hinged side thereof for retaining said door in position during handling of the assembly.
 5. A prefabricated door assembly as set forth in claim 4 wherein said angled stop member is attached to said door and to the adjacent jamb by double-headed nails.
 6. A prefabricated door assembly as set forth in claim 4 wherein said stop member includes an extension of its side engaging said jamb portion and lying between said door and said jamb portion to hold the door and jamb portion in spaced relationship.
 7. A prefabricated door assembly as set forth in claim 2 wherein each of said clamps comprises a flat metal plate having struck out portions forming said perforation and locking members, said members providing nail engaging edges extending away from the plate for affording ready passage of the nail when driven but resisting movement of the nail in the opposite direction whereby a clamping action may be provided in the initial assembly and also after driving of the nail into a stud. 